60GR Natural Gas Booster Instruction Manual 160 GR Natural Gas Booster Disassembly and Re-Assembly Instruction Manual This manual is to provide instructions how to disassemble and re-assemble the 160GR machine. Mayekawa all rights reserved. Subject to change without notice. Lat revised in October 2007 p.
160GR Natural Gas Booster Instruction Manual Contents 1. Introduction ..........................................................................................................................................4 2. Capacity Control Procedures ...............................................................................................................4 3. Variable Vi Structure ............................................................................................................................4 3.1.
160GR Natural Gas Booster Instruction Manual 8.9 Installation of speed up Spindle ..........................................................................................43 8.10 Speed up Gear Casing Cover .............................................................................................44 8.11 Balance Piston Cover ..........................................................................................................44 8.12 Unloader Cover ......................................................
160GR Natural Gas Booster Instruction Manual 1. Introduction The 160GR is a compressor engineered for the natural gas booster. Provided that it will be operated by an engine, the compressor itself has an internal speed up gear that allows different ratios according to the required air volume. Also, the Vi on the outlet port can be changed in 4 steps with the manual capacity control as the standard. 2.
160GR Natural Gas Booster Instruction Manual settings, make sure that the compressor is at a stop and that the gas inside the compressor is discharged in the air. Vi should not be changed while the compressor is running. To Change Vi Settings [CAUTIONS] ・ On this compressor, Vi should be changed after the compressor is opened to the atmosphere. ・ Vi settings should be changed while the compressor is stopped. Also, make sure the drive is not moving or will not move.
160GR Natural Gas Booster Instruction Manual b) c) d) e) f) g) Remove the guide pin from the case. When the current port is “K” or “L,” the guide pin is located in the bottom area of the suction cover. When the current port is “M” or “K”, they are located on the bottom of the rotor casing. Turn the handle as many times as required to change to the desired Vi. When changing to a higher Vi, turn the handle to the left. When changing to a lower Vi, turn the handle to the left.
160GR Natural Gas Booster Instruction Manual Number of Rotations of Handle Direction of Rotations Position of fixing pin Moving Distance (mm) Number of Rotations of Handle Direction of Rotations Position of fixing pin Moving Distance (mm) Number of Rotations of Handle Direction of Rotations Position of fixing pin 3-1/2 4‐7/8 8-1/2 Clockwise Suction Cover Counter-clockwise Rotor Casing Counter-clockwise Rotor Casing From the M Port M Port ⇒ K Port M Port ⇒ L Port 50.5 29.5 M Port ⇒ H Port 21.
160GR Natural Gas Booster Instruction Manual ・Vi Changing Procedures < From K-Port to L-Port > ① the Position of K-Port ② Remove the Variable Vi guide pin. ③ Turn the capacity control handle 3 1/2 times in counter-clockwise, and move the Variable Vi slide valve to the L-port position. ④ Screw the Variable Vi guide pin in. If it is tight, turn the handle slightly in both directions and find a loose spot. This completes the changing to L-Port. procedures Mayekawa all rights reserved.
160GR Natural Gas Booster Instruction Manual ・Vi Changing Procedures < From L-Port to M-Port > ① The position L-Port ② Remove the Variable Vi guide pin from the bottom of the suction cover. ③ Turn the capacity control handle 4 7/8 times in counter-clockwise and remove the set bolt from the bottom of the rotor casing. Replace it with Variable Vi guide pin. ④ Screw the Variable Vi guide pin into the bottom of the rotor casing. If it is tight, turn the capacity control handle slightly in both directions.
160GR Natural Gas Booster Instruction Manual 3.1.2 When the Current Port is not known When the position of the current port is not known, move the Variable Vi valve to the position of the stopper on the loading side. Then turn the handle as many times as required in order to change to the desired Vi and move the Variable Vi valve. a) Remove the Variable Vi support guide pin from the case. (The one with the larger size of the hex head (30mm) is the guide pin.
160GR Natural Gas Booster Instruction Manual Mayekawa all rights reserved. Subject to change without notice. Lat revised in October 2007 p.
160GR Natural Gas Booster Instruction Manual Each Port and the Position of the Variable Vi guide pin K-Port L-Port M-Port H-Port Mayekawa all rights reserved. Subject to change without notice. Lat revised in October 2007 p.
160GR Natural Gas Booster Instruction Manual 4. Parts Expanded View 4-1 160GR Standard Mayekawa all rights reserved. Subject to change without notice. Lat revised in October 2007 p.
160GR Natural Gas Booster Instruction Manual 4-2 160GR with Integral Pump Mayekawa all rights reserved. Subject to change without notice. Lat revised in October 2007 p.
160GR Natural Gas G Booster Instruction Maanual 4-3 Parts Structure Diagrram Mayekkawa all rights reserved. Sub bject to change e without notice e. Lat revised in October 200 07 p.
0GR Natural Gas G Booster Instruction Maanual Mayekkawa all rights reserved. Sub bject to change e without notice e. Lat revised in October 200 07 p.
160GR Natural Gas Booster Instruction Manual 5.
160GR Natural Gas Booster Instruction Manual No Name No Name 41-2 BEARING SPACER F 196-2 OIL CONTROL THROTTLE COMP FS 42-1 SPACER, THRUST BEARING M ALIGNMENT 196-3 OIL CONTROL THROTTLE COMP MD 42-2 196-5 SPACER, THRUST BEARING F ALIGNMENT OIL CONTROL THROTTLE, SPEED UP GEAR 196-4 237-C OIL CONTROL THROTTLE COMP FD TORSIONAL SLIP WASHER C 237-A TORSIONAL SLIP WASHER A 237-D TORSIONAL SLIP WASHER D 237-B TORSIONAL SLIP WASHER B 237-E TORSIONAL SLIP WASHER E 54 UNLOADER SLIDE VALVE (1
160GR Natural Gas Booster Instruction Manual 6. Outer Dimension Mayekawa all rights reserved. Subject to change without notice. Lat revised in October 2007 p.
160GR Natural Gas Booster Instruction Manual 7. Disassembly Preparation Although screw compressors are reliable machines, they need to be disassembled to have their parts inspected after operating for a certain amount of time. In this chapter, the procedures and instructions for disassembly and parts inspection will be provided. Disassembling a compressor at the installed site is limited to: the shaft seal parts, the unloader parts, and the balance piston parts.
160GR Natural Gas Booster Instruction Manual the suction cover and the bearing head. These bolts cannot be removed after the compressor is placed on the paten. Figure 1 Bolt under Suction Cover Figure 2 Bolt under Rotor Casing There is a large amount of residual oil inside the compressor. Extract the oil in advance. The oil inside can be extracted by removing the plug on the bottom of the suction cover and the rotor casing, or plug (454-2) on the suction cover.
160GR Natural Gas Booster Instruction Manual The Order of Disassembly Follow the order shown below to disassemble and inspect the compressor. The order of the compressor disassembly: 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) Mechanical shaft sea Unloader cover and unloader thrust bearing Balance piston cover Balance piston Speed up gear casing cover Speed up gear casing Thrust bearing Suction cover and side bearing Rotors Variable Vi slide valve, unloader slide valve Bearing head, main bearing 7.4.
160GR Natural Gas Booster Instruction Manual b） Remove the seal cover. The mating ring is attached to the seal cover. Keep the seal cover parallel to the shaft, in order to make sure the ring does not touch the shaft. Then, remove the “O” Ring (49) located between the seal and seal retainer. c） Inspect the shaft after the seal cover is removed. If there are scars on it, use a sand paper (#800 and above) to sand them down.
160GR Natural Gas Booster Instruction Manual 7.4.1.2 Inspection a） Inspect the sliding surfaces of the mating ring and the seal ring. If the surfaces are evenly worn, and the amount of the wear is not significant, they can be reused. However, if the wear is not even, or if there is a peel on the surfaces, they can cause the seal leak. Replace them with new parts. b） Inspect the “O” ring.
160GR Natural Gas Booster Instruction Manual Figure 10 Removing Unloader cover bolt Figure 11 Removing Variable Vi Support pin (with Suction Cover on) d） The “O” ring (82) to seal the unloader push rod (67) is installed on the unloader cover. When pulling the unloader cover out, keep the hole of the cover parallel to the unloader slide rod. Forcing the angled cover to be pulled out can damage the shaft. Use a receiver for the residual oil that may flow from the gap in the cover flange in this process.
160GR Natural Gas Booster Instruction Manual 7.4.3.1 Disassembly a） Pull out the hexagon socket head screw (81) on the unloader thrust bearing cramp (80). b） Lift the tabs of the thrust washer for the lock nut that are bent to hold the inner race Loosen and remove the lock nut (69) by using the lock nut wrench. To loosen the lock nut (69), hold the ◇ area in the front edge of the unloader push rod (67) with the spanner.
160GR Natural Gas Booster Instruction Manual 7.4.4 Balance Piston Cover 7.4.4.1 Disassembly a） Remove the top 2 hexagon socket head screws (24), and insert safety bolts. Remove all the other hexagon socket head screws (24). Figure 16 Removing Bolts on Balance Piston Cover Figure 17 Removing Balance Piston Cover b） The position of the balance piston cover (22) is determined by the alignment pin (596). There are 2 openings for the eye bolts.
160GR Natural Gas Booster Instruction Manual Figure 18 Hexagon socket head screw Figure 19 Removing Spring Retainer 7.4.5.2 Inspection a) Check the spring (83) for any defects. If there is, replace the part. 7.4.6 Balance Piston, Balance Piston Sleeve Compared with the F rotor, on the screw compressor, the M rotor receives the larger thrust load by the gas load from the discharge to the suction.
160GR Natural Gas Booster Instruction Manual Figure 20 Stop Ring on Balance Piston Figure 21 Removing Balance Piston Sleeve 7.4.6.2 Inspection Although there might be some wear on the balance piston, there is no problem unless the wear is significant. Replace the “O” ring of the balance piston sleeve. 7.4.7 Speed up Gear Casing Cover 7.4.7.1 Disassembly a） Remove the top 2 hexagon socket head screws (195) that tighten the speed up gear casing cover (171). Insert the safety bolts.
160GR Natural Gas Booster Instruction Manual d） Also, as inserting the eye bolts so that the speed up gear casing cover (171) and the speed up gear casing (169) are in a parallel, the speed up gear casing cover will be detached from the set alignment pins (19). e） Screw the suspension bolts into the speed up gear casing cover. With this bolts suspended, remove the speed up gear casing cover. Figure 24 Removing Gear Cover 7.4.7.2 Inspection Check for a bent on the alignment pins.
160GR Natural Gas Booster Instruction Manual Figure 25 Removing Support Metal Figure 26 Attaching Safety Bolts c） Insert the removed bolts into the screwed hole of the speed up gear casing (169) evenly. The speed up gear casing will be detached from the set alignment pins. d） Suspend the speed up gear casing (169) by the eyebolts and keep it in a parallel with the shaft. When removing, keep the speed up drive gear (174) and the speed up gear spindle (188) attached with the speed up gear casing.
160GR Natural Gas Booster Instruction Manual so that the speed up gear comes atop the casing. Lift the tabs of the lock washer (270) and loosen the lock nut (269) with the proper lock nut wrench. b） Flip the speed up gear casing and fix it on the platen again. Place blocks (etc.) underneath the platen to avoid collisions between the part and the ground. c） Remove the hexagon socket gland bolt (191) that tightens the speed up gear thrust bearing gland (190). Remove the thrust bearing gland.
160GR Natural Gas Booster Instruction Manual 7.4.9.2 Inspection a） Check the gear tooth surface for any remarkable hit or wear. If there is, look for the cause and replace the part. b） When there is an unusual running trace or unusual wear on the ball or the rolling surface, replace the part. 7.4.10 Spindle Roller Bearing 7.4.10.1 Disassembly a） Remove the stop ring (186) by the stop ring pliers. b） Pull out the outer-ring of the speed up gear rolling bearing (185).
160GR Natural Gas Booster Instruction Manual Figure 33 Removing Lock nut Figure 34 Removing Speed Up Driven Gear 7.4.11.2 Inspection a） Check the gear tooth surface of the drive side speed up driven gear (179) for scars and wears. 7.4.12 Thrust Bearing The thrust bearing is used to determine the direction / position of the rotor shaft and to maintain a certain space between the rotor’s discharge end face and the bearing head.
160GR Natural Gas Booster Instruction Manual Figure 35 Thrust Cramp Bolt Figure 36 Removing Thrust Gland b) Remove the thrust bearing glands 2 (43-2, 43-4). Lift the tabs of the lock washers (39-1, 39-2) for the lock nut that hold the inner-ring of the thrust bearings. Loosen and remove the lock nut with the proper lock nut wrench. Between the lock nut and the lock washer, there is a think steel sheet. Do not lose it or bend it. Also there is a washer between the lock washer and the inner-ring.
160GR Natural Gas Booster Instruction Manual 7.4.11.2 Inspection a） Wash the thrust bearing thoroughly with washing oil. Check the ball surface for tarnish, scars, peeling, flaking, and distortion. Then check the retainer for wears and distortions. Finally check the inner-ring and the running trace of the outer-ring for scars, peeling, and flaking. b） When there is even a slightest defect on the thrust bearings, replace the parts. 7.4.12 Suction Cover 7.4.12.
160GR Natural Gas Booster Instruction Manual Figure 42 Removing Suction Cover Figure 43 Removing Stop Ring d） Remove the stop rings (29-1, 29-2) with the stop ring pliers, and then remove the oil control throttles (196-1, 196-2). Next, remove the side bearings (28-1, 28-2). As the bearings are 中間 fitted, do not tilt the bearings when pulling out. Figure 44 Removing Bearing 7.4.12.2 Inspection a) Check the inner-ring and the surface of the roller bearings for tarnish, scars, and peeling.
160GR Natural Gas Booster Instruction Manual b) Use V Blocks (etc.) to support the shaft of the removed rotor. Do not place the rotor directly on the floor and damage the outer rim. c) Follow the same procedures to remove the other rotor. When pulling the rotor out, balance it well so that the rotor shaft will not be damaged.
160GR Natural Gas Booster Instruction Manual b) Check the rotor tooth for the hit and the outer rim for wears. If there is a remarkable wear, it could be that a foreign substance has entered. The suction strainer and the oil filter need to be examined. c) Inspect the unloader slide valve, the sliding surfaces and the space of the Variable Vi slide valve and the rotor casing. If there is a wear, replace the parts. d) Inspect the inside of the rotor casing.
160GR Natural Gas Booster Instruction Manual 8. Re-assembly When the inspections and repair of each part has been completed, proceed to the process of re-assembling the compressor. Reassembling process is essentially carried out in reverse order of disassembly. Use the same tools used for disassembly and pay attentions for safety. The tools to be used should be thoroughly cleaned. The parts to be assembled should be washed and lubricated before assembled. 8.
160GR Natural Gas Booster Instruction Manual 8.3 Rotor Casing, Rotor a） When replacing the main bearings and the side bearings, put shrink fit on the inner-ring with the rotor. b） Apply oil on the bearing outer-ring inserted in the bearing head and the bearing inner-ring attached to the rotor. Install the M rotor into the rotor casing first. With the use of chain blocks (etc.), suspend and the balance the rotor with a nylon sling.
160GR Natural Gas Booster Instruction Manual c） First, install the washer and the thrust adjusting washer, and proceed to the thrust bearings. Install the thrust bearings in the way that the tip of the “V” mark faces the rotor side. When the thrust bearings are facing the wrong way, the measurement of the outer-ring and the inner-ring change. The inaccuracy in the measurement will change the end clearance from the value before the disassembly. d） Install the thrust washer and the lock washer.
160GR Natural Gas Booster Instruction Manual b） Install the driven side speed up gear, the driven side gear spacer, the lock washer, and the packing in this order. Then use a wrench to tighten the lock nut. c） Then, make sure the vibration on the journal area of the shaft edge with a dial indicator by turning the rotor by hand. The allowable range of the vibration is within 0.33mm. When the measurement is beyond the allowable range, loosen the lock nut.
160GR Natural Gas Booster Instruction Manual Spindle Thrust Bearing Lock nut : Torque Lock nut (AN13)Tightening Torque General (N・m) 160GLR 512 Max.(N・m) 640 Thrust Bearing Cramp : Torque Speed up Gear Thrust Cramp Torque Set Value(N・m) 160GLR 49.0 8.10 Speed up Gear Casing Cover a） Install the side bearing for the speed up gear in the speed up gear casing. There is a set pin in the back. Match the pin with the notch on the side bearing when installing.
160GR Natural Gas Booster Instruction Manual fix the cramp up to the specified torque, by gradually and evenly tighten them in diagonal. If the bolts are tightened to the specified torque one by one, the cramp will not be fixed evenly. Alternate to tighten the 4 bolts to reach the specified torque. c） Attach the gasket. Join the unloader cover with the outer-rim of the unloader thrust bearing cramp, and fix them with the hexagon socket head screws. 8.
160GR Natural Gas Booster Instruction Manual specified value. Use iron for shim. II. When the end clearance is smaller than the specified value When the rotor does not move with only the tightened lock nuts, the cause is either the lack in the thickness of the thrust adjusting washer or the excess thickness of the spacer. a） When the end clearance is small, insert a shim between the thrust adjusting washer and the inner-ring of the bearings.
